Connector mechanisms for surgical stapling instruments

ABSTRACT

A surgical stapling instrument includes a body portion and a tool assembly extending from the body portion. The tool assembly includes a jaw member, and a first connector assembly disposed within the jaw member. The first connector assembly includes a first connector housing and first and second connector members extending from the first connector housing. The surgical stapling instrument further includes a cartridge assembly selective receivable within the jaw member. The cartridge assembly includes a second connector assembly configured for electrical connection with the first connector assembly. The second connector assembly includes a second connector housing and first and second contact members disposed within the second connector housing. The first and second connector members of the first connector assembly are configured to engage the respective first and second contact members of the second connector housing when the cartridge assembly is received within the jaw member of the tool assembly.

BACKGROUND Technical Field

The present disclosure relates to surgical stapling instruments including a replaceable cartridge assembly having an identification chip. More particularly, the present disclosure relates to electrical connectors for connecting the identification chip of a cartridge assembly of a surgical stapling instrument with a handle assembly of the stapling instrument.

Background of Related Art

Surgical stapling instruments for applying rows of surgical staples to tissue are well known in the art and typically include a powered handle assembly, a body portion extending distally from the handle assembly, and a stapling end effector that is supported on a distal end of the body portion and is articulable relative to the body portion. The stapling end effector includes first and second jaws which are movable in relation to each other between spaced and approximated positions. The first jaw supports an anvil assembly and the second jaw supports a cartridge assembly. The cartridge assembly may be replaceable to permit reuse of the end effector during a surgical procedure. The replaceable cartridge assembly may be provided in a variety of configurations for use on tissue having different properties, e.g., thickness, density. For example, the different cartridge assemblies may have different size staples and/or different configurations of staples.

Many cartridge assemblies include an identification chip that is electrically coupled to the handle assembly by a conductor extending through the body portion of the surgical stapling instrument to ensure the handle assembly is programmed to operate with the attached cartridge assembly. During attachment of the cartridge assembly to the surgical stapling instrument improper loading of the cartridge assembly may result in damage to the electrical connection between the cartridge assembly and the surgical stapling instrument. Similarly, exposure of the electrical connection to fluids during a surgical procedure may damage and significantly affect operation of the surgical stapling instrument. To prevent damage to the electrical connections during loading of the cartridge assembly and during use of the surgical stapling instrument, it would be beneficial to provide a cartridge assembly with improved electrical connections.

SUMMARY

Accordingly, a surgical stapling instrument including a connector mechanism is provided. The surgical stapling instrument includes a proximal body portion configured for operable engagement with a handle assembly and a tool assembly extending from the proximal body portion. The tool assembly includes an anvil assembly, a jaw member pivotally secured relative to the anvil assembly, and a first connector assembly disposed within the jaw member. The first connector assembly includes a first connector housing and first and second connector members extending from the first connector housing. The surgical stapling instrument further includes a cartridge assembly selective receivable within the jaw member of the tool assembly. The cartridge assembly includes a second connector assembly configured for electrical connection with the first connector assembly when the cartridge assembly is received within the jaw member. The second connector assembly includes a second connector housing and first and second contact members disposed within the second connector housing. The first and second connector members of the first connector assembly are configured to engage the respective first and second contact members of the second connector housing when the cartridge assembly is received within the jaw member of the tool assembly.

In embodiments, the cartridge assembly includes a cartridge body and a support plate. The surgical stapling instrument may further include a handle assembly operably secured to the proximal body portion. The first and second connector assemblies may form a connector mechanism for electrically connecting the cartridge assembly with the handle assembly. The first and second connector members may each include a beveled leading edge.

In some embodiments, the first and second contact members each includes a coil spring. Alternatively, the first and second contact members may each include a leaf spring. Each of the leaf springs may include an inclined engagement surface. Each of the leaf springs may be configured to be deflected inward upon engagement with the respective first or second connector member.

The second connector assembly of the cartridge assembly may include a seal member support on the second connector housing. The seal member may include first and second apertures for receiving the first and second connector members of the first connector assembly. The seal member may provide a cleaning action when the first and second connector members are received through the first and second apertures. The cleaning action may be a squeegee or wiping action.

The first connector assembly may be secured to the jaw member by a flange and post connection. The second connector assembly may include an identification chip. Specifications of the cartridge assembly may be loaded on the identification chip.

BRIEF DESCRIPTION OF THE DRAWINGS

Various embodiments of the connector mechanism of the present disclosure are described herein with reference to the drawings, wherein:

FIG. 1 is a perspective view of a surgical stapling instrument including a loading unit having a connector mechanism according to an embodiment of the present disclosure;

FIG. 2 is a side, perspective view of the loading unit of the surgical stapling instrument shown in FIG. 1;

FIG. 3 is a front, perspective view of the loading unit shown in FIG. 2 with a cartridge assembly of the loading unit, including a shipping wedge, prior to being loaded into a jaw member of the loading unit;

FIG. 4 is a side perspective end view of the cartridge assembly shown in FIG. 3;

FIG. 5 is an enlarged view of the indicated area of detail shown in FIG. 3 including a first connector assembly;

FIG. 6 is an enlarged view of the indicated area of detail shown in FIG. 4 including a second connector assembly;

FIG. 7 is a side perspective view of the first connector assembly shown in FIG. 3 secured within the jaw member of the loading unit shown in FIG. 2;

FIG. 8 is an enlarged view of the indicated area of detail shown in FIG. 7;

FIG. 9 is a side perspective view of the first connector assembly and a proximal portion of the jaw member shown in FIG. 7 with parts separated;

FIG. 10 is a side perspective view of the first connector assembly shown in FIG. 9;

FIG. 11 is a perspective view of a second connector assembly and a proximal portion of the cartridge assembly shown in FIG. 4;

FIG. 12 is a perspective view of the second connector assembly and the proximal portion of the cartridge assembly shown in FIG. 11 with parts separated;

FIG. 13 is an end perspective view of a second connector assembly according to an embodiment of the present disclosure;

FIG. 14 is an end perspective view of a second connector assembly according to another embodiment of the present disclosure;

FIG. 15 is a cross-sectional view taken along section line 15-15 of FIG. 14;

FIG. 16 is a side perspective view of the loading unit shown in FIG. 2 including the first connector assembly shown in FIG. 3 and the second connector assembly shown in FIG. 4 and an anvil assembly shown in phantom;

FIG. 17 is a cross-sectional end view of the second connector assembly shown in FIG. 13 taken along line 17-17 shown in FIG. 16; and

FIG. 18 is a cross-sectional end view of the second connector assembly taken along line 18-18 shown in FIG. 16.

DETAILED DESCRIPTION OF THE DRAWINGS

Embodiments of the presently disclosed connector mechanism for a surgical stapling instrument will now be described in detail with reference to the drawings wherein like reference numerals designate identical or corresponding elements in each of the several views. In this description, the term “proximal” is generally used to refer to the portion of the instrument that is closer to a clinician, while the term “distal” is generally used to refer to the portion of the instrument that is farther from the clinician.

The embodiments of the present disclosure address an improved connection between a replaceable cartridge assembly and a tool assembly of a surgical stapling instrument.

FIG. 1 illustrates a surgical stapling instrument including a connector mechanism according to an exemplary embodiment of the present disclosure shown generally as surgical stapling instrument 10. Although illustrated as a surgical stapling instrument, aspects of the present disclosure may be modified for use with other types of end effectors that include a replaceable unit that electrically communicates with a handle assembly. The surgical stapling instrument 10 includes a powered handle assembly 12, an adapter assembly 14, and a loading unit 100. The handle assembly 12 and the adapter assembly 14 are configured to effect operation of the loading unit 100. For a detailed description of the structure and function of exemplary handle and adapter assemblies, please refer to commonly owned U.S. Pat. No. 9,055,943 (“the '943 Patent”), the content of which is incorporated by reference herein in its entirety. Although the loading unit 100 is shown and described as being selectively secured to the adapter assembly 14 of the surgical stapling instrument 10, it is envisioned that the loading unit 100 may be supported directly on the distal end of the adapter assembly 14, and/or supported directly by the handle assembly 12.

Referring to FIGS. 1 and 2, the loading unit 100 includes a proximal body portion 102 and a tool assembly 104. A mounting assembly 106 is secured to the tool assembly 104 and is pivotally coupled to the proximal body portion 102 of the loading unit 100 to pivotally secure the tool assembly 104 to the proximal body portion 102. The loading unit 100 is substantially as described in U.S. Pat. App. Pub. No. 2016/0249929 (“the '929 Publication”). The '929 Publication is hereby incorporated by reference herein in its entirety. Accordingly, the loading unit 100 will only be described to the extent necessary to fully disclose the aspects of the present disclosure.

With reference to FIGS. 3-6, the tool assembly 104 of the loading unit 100 includes an anvil assembly 108 and a replaceable cartridge assembly 120 receivable within a jaw member 110 of the tool assembly 100. The anvil assembly 108 and the jaw member 110 are movable in relation to each other between an open position (FIG. 2) and an approximated position (FIG. 16). The cartridge assembly 120 includes a support plate 122 and a cartridge body 124 securely received within the support plate 122. The cartridge body 124 supports a plurality of staples (not shown). A shipping member 126 is releasably secured to the cartridge body 124 to retain the staples within the cartridge body 124 and/or to prevent premature firing of the loading unit 100.

The cartridge body 124 and the support plate 122 are attached to the jaw member 110 by a snap-fit connection as described in the '943 Patent, which has been incorporated herein by reference. Other forms of securing the cartridge assembly 120 to the jaw member 110 are contemplated and may be used in place of the snap-fit connection or in addition thereto.

The tool assembly 104 of the loading unit 100 includes a connector mechanism 130 (FIG. 16) having a first or male connector assembly 140 disposed within the jaw member 110 (FIG. 5) and a second or female connector assembly 160 (FIG. 6) secured to the cartridge assembly 120. As will be described in further detail below, when the cartridge assembly 120 is loaded into the jaw member 110 of the loading unit 100, the second connector assembly 160 of the connector mechanism 130 electrically couples with the first connector assembly 140 of the connector mechanism 130 to provide specifications of the cartridge assembly 120 to the handle assembly 12 (FIG. 1) of the surgical stapling instrument 10, e.g., staple size, number and/or configuration.

Turning now to FIGS. 7-9, the jaw member 110 of the tool assembly 106 (FIG. 1) of the loading unit 100 defines a channel 111 for receiving the cartridge assembly 120 (FIG. 4). The jaw member 110 includes a flange 112 (FIG. 9) extending within the channel 111. As will be described in further detail below, a tab 112 a (FIG. 8) on a free end of the flange 112 is configured to secure the first connector assembly 140 of the connector mechanism 130 (FIG. 15) within the channel 111. The jaw member 110 defines an opening 113 (FIG. 9) disposed adjacent to the flange 112 for receiving a boss 144 (FIG. 10) of the first connector assembly 140.

With additional reference to FIG. 10, the first connector assembly 140 of the connector mechanism 130 includes a first connector housing 142. The first connector housing 142 defines a slot 143 through which the flange 112 of the jaw member 110 of the tool assembly 106 is received. As shown in FIG. 8, when the flange 112 of the jaw member 110 is received through the slot 143 in the first connector housing 142, a tab 112 a formed or supported on the free end of the flange 112 engages the first connector housing 142 to secure the first connector assembly 140 to the jaw member 110. In this manner, the first connector assembly 140 is secured to the jaw member 110 with a snap retention. The first connector housing 142 includes the boss 144. As noted above, the boss 144 is configured to be received within the opening 113 (FIG. 9) in the jaw member 110 when the flange 112 is received within the slot 143. Receipt of the boss 144 of the first connector housing 142 in the opening 113 in the jaw member 110 provides additional torque resistance for the first connector assembly 140 during loading of the cartridge assembly 120 within the jaw member 110.

Although shown with the first connector assembly 140 being secured to the jaw member 110 of the tool assembly 106 by the flange 112 and opening 113, it is envisioned that the first connector assembly 140 may be secured to the jaw member 110 in any suitable manner. For example, the first connector assembly 140 may be heat staked, bonded, welded, or otherwise secured to the jaw member 110.

With continued reference to FIG. 10, first and second connector members 146, 148 extend outwardly from the first connector housing 142 and are positioned and configured to engage the second connector assembly 160 (FIG. 6) of the connector mechanism 130 when the cartridge assembly 120 is received within the channel 111 of the jaw member 110. In embodiments, and as shown, a leading portion 146 a, 148 a of each of the first and second connector members 146, 148, respectively, are beveled to facilitate engagement of the first connector assembly 140 with the second connector assembly 160 of the connector mechanism 130. In embodiments, the first and second connector members 146, 148 measure about 0.05 inches by 0.015 inches in size and are formed by folding 0.0075 inch thick sheet metal. In embodiments, the first and second connector members 146, 148 are be spaced 0.050 inches apart. Alternately, other dimensional characteristics are envisioned.

With reference to FIGS. 11 and 12, the cartridge body 124 of the cartridge assembly 120 includes a projection 126 extending from a proximal portion 124 a of the cartridge body 124. The projection 126 defines a recess 127 for receiving the second connector assembly 160 of the connector mechanism 130. The projection 126 further defines a notch 127 a opposite the open end of the recess 127. The notch 127 a is configured to receive a tab 166 a of the second connector housing 162 to secure the second connector housing 162 to the cartridge body 124. The projection 126 is configured such that when the second connector assembly 160 is received within the recess 127 and the cartridge assembly 120 is loaded into the jaw member 110, the second connector assembly 160 engages the first connector assembly 140 that is secured to the jaw member 110.

The second connector assembly 160 includes a second connector housing 162 having a base portion 164 and an extension portion 166 and defines first and second recesses 163, 165 (FIG. 15). As will be described in further detail below, first and second contact members, e.g., coil springs 182, 184 (FIG. 13) or leaf springs 192, 194 (FIG. 15), are operably disposed within the respective first and second recesses 163, 165 (FIG. 13) or 163′, 165′ (FIG. 15).

A seal member 168 may be secured to the base portion 164 of the second connector housing 162 of the second connector assembly 160. In embodiments, and as shown, the seal member 168 (FIG. 12) is over molded to the base portion 164 of the second connector housing 162. Alternatively, the seal member 168 may include a perimeter bead, e.g., O-ring or the like, that is adhered or otherwise secured to the connector housing 162. The seal member 168 defines first and second apertures 167, 169 for providing access to the first and second contact members, e.g., coil springs 182, 184 (FIG. 13) or leaf springs 192, 194 (FIG. 15), respectively, received within the first and second recesses 163, 165 in the second connector housing 162. In addition to providing a seal between the second connector housing 162 of the second connector assembly 160 and the first connector housing 142 of the first connector assembly 140, the seal member 168 may provide a cleaning action, e.g., squeegee or wiping action, as the first and second connector members 146, 148 (FIG. 5) are received through the respective first and second apertures 167, 169 of the seal member 168. The seal member 168 may also provide electrostatic discharge protection to the loading unit 100 and the surgical stapling instrument 10 (FIG. 1).

The extension 166 of the second connector housing 162 of the second connector assembly 160 includes a tab 166 a (FIG. 11) for securing the second connector housing 162 within the recess 127 in the projection 126 of the cartridge body 124. More particularly, the tab 166 a of the second connector housing 162 is received within the notch 127 a formed in the projection 126 when the extension 166 of the second connector housing 162 is received within the recess 127 to secure the second connector housing 162 within the projection 126 with a snap retention.

The second connector assembly 160 further includes an identification chip 170 (FIG. 13). The identification chip 170 may be disposed within the base portion 164 of the second connector housing 162 or within the extension portion 166 of the second connector housing 162, or may extend between the base 164 and the extension 166. Alternatively, the identification chip 170 may be disposed elsewhere within the cartridge assembly 120, and be electrically connected to the second connector assembly 160 using suitable methods.

The identification chip 170 may include any commercially available chip capable of storing information including specifications of the cartridge assembly 120, e.g., cartridge size, staple arrangement, staple length, clamp-up distance, production date, model number, lot number, expiration date, etc., and transmitting at least some of the information to the handle assembly 12 (FIG. 1). In one embodiment, the identification chip 170 includes an erasable programmable read only memory chip (“EPROM” or “EEPROM”). In embodiments, the EPROM is erasable with UV and the EEPROM is erasable with electricity. In this manner, the configuration of an attached cartridge assembly 120 may be relayed to the handle assembly 12 such that, for example, the firing forces and/or the length of the firing stroke of the handle assembly 12 may be adjusted to accommodate the particular cartridge assembly 120.

It is envisioned that instead of an EPROM or EEPROM, the identification chip 170 may be a read/write memory chip, such as read/write RAM, such that data may be written onto the identification chip 170. For example, usage information may be written onto the identification chip 170 that identifies that the loading unit 100 has been fully or partially fired to prevent reuse of an empty or partially fired loading unit, or for any other purpose.

Turning to FIG. 13, in a first embodiment of the second connector assembly 160, the first and second contact members include the first and second coil springs 182, 184. The first and second coil springs 182, 184 are received within respective first and second recesses 163, 165 of the second connector housing 162. The first and second coil springs 182, 184 are configured to be engaged by the respective first and second connector members 146, 148 of the first connector assembly 140 during receipt of the cartridge assembly 120 within the jaw member 110. As the first and second connector members 146, 148 engage the respective first and second coil springs 182, 184, the first and second coil springs 182, 184 compress, as indicated by arrow “A” in FIG. 17, to ensure electrical contact between the first and second connector members 146, 148 and the respective first and second coil springs 182, 184.

In embodiments, the first and second coil springs 182, 184 are compression springs. For example, the first and second springs 182, 184 may be compressions springs provided by Lee Spring of the United Kingdom. In embodiments, the compression springs may have an outside diameter of 0.024 inches, a hole diameter of 0.031 inches, a wire diameter of 0.004 inches, a free length of 0.039 inches, a rate of compression of 11.24 pounds/inch, a solid length of 0.026 inches, a rod diameter of 0.012 inches, and/or may be formed of stainless steel or other suitable conductive material. Alternately, other spring types and dimensions are envisioned.

Turning to FIGS. 14-18, in a second embodiment of the second connector assembly 160, the first and second contact members include first and second leaf springs 192, 194. The first and second leaf springs 192, 194 are received within respective first and second recesses 163′, 165′ (FIG. 15) of a second connector housing 162′. The first and second leaf springs 192, 194 are configured to be engaged by the respective first and second connector members 146, 148 of the first connector assembly 140 during receipt of the cartridge assembly 120 within the jaw member 110 of the loading unit 100. As the first and second connector members 146, 148 engage the respective first and second leaf springs 192, 194, engagement portions 192 b, 194 b of the first and second leaf springs 192, 194 deflect inwardly, as indicated by arrows “B” and “C”, respectively, shown in FIG. 18, to ensure electrical contact between the first and second connector members 146, 148 and the respective first and second leaf springs 182, 184.

In embodiments, and as shown, the first and second leaf springs 192, 194 each include an elongate body portion 192 a, 194 a, respectively, and the engagement portion 192 b, 194 b, respectively. Each engagement portion 192 b, 194 b may include an inclined surface 193, 195 to facilitate inward deflection of the respective first and second leaf springs 192, 194, as indicated by arrows “B” and “C”, respectively, shown in FIG. 18. In embodiments, the first and second leaf springs 192, 194 are formed from 17-7PH RH 950 material and/or include a thickness of 0.005 inches. In embodiments, the first and second leaf springs 192, 194 are configured to deflect 0.020 inches. Alternately, other spring types and characteristics are envisioned.

With reference to FIG. 16, the loading unit 100 is shown with the cartridge assembly 120 received within the jaw member 110 of the tool assembly 104. When the cartridge assembly 120 is received within the jaw member 110, the second connector assembly 160 of the connector mechanism 130 engages the first connector assembly 140 of the connector mechanism 130. More particularly, and with reference to FIG. 17, when the cartridge assembly 120 is received within the jaw member 110, the first and second connector members 146, 148 (FIG. 5) of the first connector assembly 140 engage the first and second coil springs 182, 184 (FIG. 13) of the second connector assembly 160 to cause compression of the first and second coil springs 182, 184, as indicated by arrow “A” in FIG. 17, to ensure an electrical connection between the first and second connector members 146, 148 and the respective first and second coil springs 182, 184.

As noted above, the seal member 168 on the base portion 164 of the second connector housing 162 provides a cleaning action, e.g., squeegee or wiping action, to remove any debris from the respective first and second connector members 146, 148 as the first and second connector members 146, 148 are received through respective apertures 167, 169 (FIG. 6) in seal member 168.

Alternatively, with reference to FIG. 18, when the cartridge assembly 120 is received with the jaw member 110, the first and second connector members 146, 148 of the first connector assembly 140 engage the first and second leaf springs 192, 194, respectively of the second connector assembly 160 to cause inward deflection of the first and second leaf springs 192, 194, as indicated by arrows “B” and “C” in FIG. 18, respectively, to ensure an electrical connection between the first and second connector members 146, 148 and the respective first and second leaf springs 192, 194. Either or both of the beveled leading edges 146 a, 148 a of the respective first and second connector members 146, 148 and/or the inclined surfaces 193, 195 of the respective first and second leaf springs 192, 194 facilitate inward deflection of the first and second leaf springs 192, 194.

Once the cartridge assembly 120 properly loaded within the jaw member 110 of the tool assembly 104 of the loading unit 100, the surgical stapling instrument 10 (FIG. 1) operates in a traditional manner.

Persons skilled in the art will understand that the devices and methods specifically described herein and illustrated in the accompanying drawings are non-limiting exemplary embodiments. It is envisioned that the elements and features illustrated or described in connection with one exemplary embodiment may be combined with the elements and features of another without departing from the scope of the present disclosure. As well, one skilled in the art will appreciate further features and advantages of the disclosure based on the above-described embodiments. Accordingly, the disclosure is not to be limited by what has been particularly shown and described, except as indicated by the appended claims. 

1. A surgical stapling instrument comprising: a proximal body portion configured for operable engagement with a handle assembly; a tool assembly extending from the proximal body portion, the tool assembly including an anvil assembly, a jaw member pivotally secured relative to the jaw member, and a first connector assembly disposed within the jaw member, the first connector assembly including a first connector housing and first and second connector members extending from the first connector housing; and a cartridge assembly selective receivable within the jaw member of the tool assembly, the cartridge assembly including a second connector assembly configured for electrical connection with the first connector assembly when the cartridge assembly is received within the jaw member, the second connector assembly including a second connector housing and first and second contact members disposed within the second connector housing, wherein the first and second connector members of the first connector assembly are configured to engage the respective first and second contact members of the second connector housing when the cartridge assembly is received within the jaw member of the tool assembly.
 2. The surgical stapling instrument of claim 1, wherein the cartridge assembly includes a cartridge body and a support plate.
 3. The surgical stapling instrument of claim 1, further including a handle assembly operably secured to the proximal body portion.
 4. The surgical stapling instrument of claim 3, wherein the first and second connector assemblies form a connector mechanism for electrically connecting the cartridge assembly with the handle assembly.
 5. The surgical stapling instrument of claim 1, wherein the first and second connector members each include a beveled leading edge.
 6. The surgical stapling instrument of claim 1, wherein the first and second contact members each include a coil spring.
 7. The surgical stapling instrument of claim 1, wherein the first and second contact members each include a leaf spring.
 8. The surgical stapling instrument of claim 7, wherein each of the leaf springs includes an inclined engagement surface.
 9. The surgical stapling instrument of claim 8, wherein each of the leaf springs is configured to be deflected inward upon engagement with the respective first or second connector member.
 10. The surgical stapling instrument of claim 1, wherein the second connector assembly includes a seal member support on the second connector housing.
 11. The surgical stapling instrument of claim 10, wherein the seal member includes first and second apertures for receiving the first and second connector members of the first connector assembly.
 12. The surgical stapling instrument of claim 11, wherein the seal member provides a cleaning action when the first and second connector members are received through the first and second apertures.
 13. The surgical stapling instrument of claim 12, wherein the cleaning action is a squeegee or wiping action.
 14. The surgical stapling instrument of claim 1, wherein the first connector assembly is secured to the jaw member by a flange and post connection.
 15. The surgical stapling instrument of claim 1, wherein the second connector assembly includes an identification chip, specifications of the cartridge assembly being loaded on the identification chip. 